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Tig torch cups

What's the general thoughts on the size of the tig torch cup openings. Currently I'm using a #5 with a 1/16th electrode. What does the number 4 or 6 ect offer above the others. Is there a general rule of thought on the electrode size and the size of the opening of the torch cup. I don't seem to have a contamination issue with any of the different cups I have been using.

Depending on the material being welded, the cup size may vary. I don't know if there is a general rule, but for instance, when you are cup walking on stainless or steel, you start with a smaller cup and graduate up in the sizes each pass to help 'roll over top' of the previous past. For free hand welding aluminum or ferous metals, I stick to one size of cup. With a 1/16" electrode, I usually use a 1/4" to 3/8" ID cup. I don't know the # sizes of cups so I can't help you there.

I believe the cups are measured in 10th's. like a #5 is 1/2". I am pretty sure thats how it works, feel free to correct me if I am wrong.
Back to the original question. I think you need to decide the cup # according to the weld and material. I am sure alot of this is personal choice. I tend to run smaller cups then others, unless I am welding aluminum, I then run a bigger (say 7) . It may be my opinion , but I always felt the extra gas around the weld area helped keep contamination down.

Kind'a crazy for me on the cup size thing.... I been using a 6 or a 7 for years with 3/32 or 1/8 but since I started working a "regular" job besides my own biz I've started using a 5 with 1/8th tungstan and tapered the tip down to about 1/16th. Burning on aluminum 1/8" to 3/16" thick all day in all types of joints both standing and sitting for 4 ten hour days!
I would never have done that on my own and looking at charts I see it's for like 1/16 tung but when you taper the tung. it helps. Using this setup allows for making a narrower bead and able to dig deep real quick. I have found on a 250 syncrowave setting almost all the way over on max penetration works best on the balance.
One thing is for sure I learned is wherever I go to work I always learn some new stuff and at my present job (ambulance body mfg) I had to get faster to keep up with the parts thrown at me and to get them to the guys waiting on my parts. I make all the doors and a normal ambulance has about ten of them...some more some less. I also just by default welded so much more in a production setting improved my tig welds from what I would have called above average to awesome.The pay sucks but it's sor'ta like being back in school so in a nutshell ...all those charts are great but nothing beats burning rod and asking questions (as you are doing gearhead) I hope that helps!

In general, a nozzle opening is about four times the electrode diameter.

there are ofcorse specilty aplications and cups as well as trailing cups and even some new stuff out that is like a steel plate with holes to alow gas flow for better trailing gas.
hope this is of some help.

thanks for the help
......or..........
hope i helped feel free to shoot me an e-mail direct i have time to chat.james@newyorkmetalart.comsummer is here, plant a tree. if you don't have space or time to plant one sponsor some one else to plant one for you. a tree is an investment in our planet, help it out.
JAMES